Ford prepping software fix to boost real-world mileage for hybrids

Since launching its third-generation hybrid system last fall on the 2013 C-Max and Fusion, Ford has seen a huge boost in sales of its electrified models, thanks in part to the 47-mpg Environmental Protection Agency mileage estimates. Unfortunately, the good news was blunted by withering criticism from reviewers and customers when the cars delivered disappointing observed fuel economy.

Raj Nair, Ford's group vice president for global product development, announced that the automaker would soon issue a software update for its 2013 model hybrids specifically designed to boost efficiency in real-world driving. Hybrid engineers at Ford are taking advantage of the fact that these drive systems are particularly sensitive to both software calibration and driving technique to make some adjustments.

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Many drivers have reported average fuel economy in the range of 35 to 40 mpg despite the lofty EPA-approved estimates of 47 mpg for the city, highway, and combined cycles on the C-Max and Fusion hybrids. Until now, those cars have been capable of running on battery power alone at up to 62 mph, which was ideal for the 48.2-mph average speed of the EPA highway drive cycle.

Most highways in the United States have a 70-mph speed limit and many drivers routinely travel faster than the posted limits. The software update will let the hybrids shut off the engine at speeds up to 85 mph, matching the top electric speed available in Ford's plug-in hybrid variants. The controls for the active grille shutters have been tweaked to close them more often, cutting aerodynamic drag at highway speeds. The changes also cut parasitic losses by reducing the cooling fan speed and adjusting the climate control system.

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In all likelihood, Ford engineers took a conservative approach to the new hardware, opting not to use these settings at launch in the interest of reliability and durability.

Ford and the EPA have not yet announced any updated fuel economy numbers for the 2014 hybrid models, so it's unclear whether the pending updates will impact the 47 mpg values on the window sticker. Going forward, the EPA will probably pay closer attention to the test procedures and results when the cars are re-evaluated, so a reduction is not out of the question. Any updated estimates should be available soon as 2014 models will be on their way to dealers any day now.